A gantry crane is the most practical lifting option for precast concrete yards. It sits on ground rails, needs no building runway, and covers the wide outdoor areas where wall panels, beams, pipes, and poles are cast and stored. I have helped plan gantry systems for over a dozen precast plants from Southeast Asia to the Middle East. The same questions come up every time: what capacity, what span, single or double girder, and what will it cost. This guide gives real specs and prices.
How Precast Yards Use Gantry Cranes
A precast concrete yard is an outdoor storage and handling area. Concrete elements get cast in molds, cured, then moved to storage and eventually loaded onto trucks. Gantry cranes do all of this — stripping molds, stacking finished products, loading transport.
The yard layout typically has parallel casting beds or storage rows. The gantry crane runs on rails between them. One crane covers one or two rows. Bigger yards use multiple cranes on parallel runways or one long-span crane that covers the whole yard.
Most precast yards I have visited run the crane on ground-level rails with a concrete foundation. Wall-mounted runways are rare. These are outdoor operations — the crane needs to travel across the full yard length, not just along a building wall.
Capacity Requirements by Product Type
This is where most buyers get stuck. The crane has to handle the heaviest product in the yard, and also lift awkward shapes — long panels, bulky pipe sections. Here is a breakdown by common precast products:
| Product Type | Typical Weight | Recommended Capacity | Notes |
|---|---|---|---|
| Wall panels | 2–15 ton | 10–20 ton | Long, thin sections — need spreader beam |
| Floor slabs / hollow-core | 3–12 ton | 10–16 ton | Wide profile, multiple lifting points |
| Precast beams | 10–50 ton | 20–50 ton | Heavy, need double girder for hook height |
| Columns | 8–40 ton | 16–50 ton | Tall sections, need extra lifting height |
| Concrete pipes | 2–25 ton | 10–32 ton | Cylindrical, need C-hook or spreader |
| Railway sleepers | 0.3–1 ton | 5–10 ton | Multi-pick batch handling |
| Concrete poles | 1–8 ton | 10–16 ton | Long, slender — need balanced pick |
Rule of thumb I use: take the heaviest single concrete element you plan to cast, add 25% for safety margin, and round up to the nearest standard crane capacity (10, 16, 20, 32, 50, or 75 ton). Most yards undersize their crane and regret it within two years when they take on heavier products.
Single Girder vs Double Girder for Precast Yards
I get asked this on almost every project. Here is how I break it down:
| Factor | Single Girder | Double Girder |
|---|---|---|
| Capacity range | Up to 20 ton | 5–100+ ton |
| Hook lift height | Lower (girder below trolley) | Higher (trolley rides on top) |
| Cost (10 ton, 25 m span) | USD 14,000–22,000 | USD 24,000–38,000 |
| Maintenance | Easier — single girder to inspect | Two girders, more components |
| Double-hook option | Limited — usually not available | Standard — main + aux hoist |
| Best for | Wall panels, slabs, sleepers | Beams, columns, pipes, mixed loads |
For a yard that only makes wall panels and floor slabs under 20 ton, single girder is fine and saves money. For yards handling beams, columns, pipes, or a mix of products, spring for double girder. Worth it.
Span and Yard Layout Planning
Span is the distance between the two gantry legs. Getting it right matters more than most people think. Too narrow and you cannot access your storage rows. Too wide and you pay for steel you do not use.
Here is how we normally calculate span for a precast yard:
| Yard Configuration | Typical Span | Storage Coverage |
|---|---|---|
| Single row of casting beds | 15–22 m | One bed + truck access on one side |
| Two rows with center aisle | 22–30 m | Two beds + center truck lane |
| Multiple rows (large yard) | 30–40 m | 3–4 storage rows + access lanes |
| Pipe / pole storage yard | 20–30 m | Racked storage + forklift access |
A common mistake: planning the span for current products only, without leaving room for wider molds or larger storage racks later. Leaving 2–3 m extra on each side adds maybe 10–15% to the crane cost but avoids a total replacement in year 3.
Double-Hook and Custom Configurations
In a typical precast yard, not all loads are the same weight. A 32-ton beam and a 5-ton mold might sit on the same storage row. Running a 32-ton crane for a 5-ton lift wastes energy and wears the hoist unevenly.
The fix: a double-hook trolley. A main hoist rated for your heaviest product and an auxiliary hoist rated for lighter loads. Both run on the same set of trolley rails. The operator picks the right hook for the load.
SIEC offers double-hook configurations as a standard option. Typical combos:
- 32 ton + 10 ton — for beam yards with mixed molds
- 20 ton + 5 ton — for wall panel and slab plants
- 50 ton + 16 ton — for heavy beam and column production
- 16 ton + 5 ton — for pipe yards with separate pipe and fitting handling
The auxiliary hoist adds roughly 15–20% to the trolley cost but eliminates the need for a separate light-duty crane. Most of our precast yard customers choose this option.
Pricing Guide for Precast Yard Gantry Cranes (2026)
Prices below are ex-works China for a standard gantry crane with electric wire rope hoist, pendant or remote control, and safety systems. Installation, rail, foundation, and electrical work add 20–35% depending on local conditions.
| Configuration | Capacity | Span | Lifting Height | Price (USD) |
|---|---|---|---|---|
| Single girder gantry | 10 ton | 20 m | 8 m | 14,000–22,000 |
| Single girder gantry | 16 ton | 25 m | 9 m | 20,000–32,000 |
| Double girder gantry | 20 ton | 25 m | 10 m | 28,000–45,000 |
| Double girder gantry | 32 ton | 28 m | 11 m | 38,000–60,000 |
| Double girder gantry | 50 ton | 30 m | 12 m | 55,000–95,000 |
| Double girder gantry | 75 ton | 32 m | 14 m | 80,000–140,000 |
| Double girder gantry | 100 ton | 35 m | 16 m | 110,000–180,000 |
Note on installation: Rail installation costs roughly USD 80–150 per meter per rail (materials + labor). Foundation and electrical vary widely by region. In Southeast Asia, total installed cost typically runs 22–28% above equipment price. In the Middle East and Europe, expect 28–35%.
Typical Installation Cost Breakdown (20-ton Double Girder, 25 m Span)
To give a concrete example, here is a full installed cost estimate for a mid-size precast yard crane:
| Item | Cost (USD) |
|---|---|
| Double girder gantry crane (20 ton, 25 m span) | 35,000 |
| Ground rails (50 m × 2 rails) | 8,000–12,000 |
| Concrete foundation for rails | 3,500–5,500 |
| Electrical installation and control panel | 2,500–4,000 |
| Installation labor and crane erecting | 4,000–7,000 |
| Shipping (FCL, port to site) | 2,500–5,000 |
| Total installed | 55,500–68,500 |
Precast Yard Gantry Crane Buyer Checklist
Before you send out RFQs, run through this list. It saves time and avoids the back-and-forth that drags out procurement:
- List every product type you currently make and plan to make in the next 3 years. Write down the heaviest weight, longest length, and handling method (spreader, C-hook, slings).
- Define your yard layout. Draw the casting beds, storage rows, truck loading area, and any fixed obstacles. Mark where the crane rails will go.
- Choose the capacity based on the heaviest product + 25% safety margin. Round up to the next standard size.
- Decide the span by measuring your widest storage row + truck access lane + 2 m clearance on each side.
- Check the hook lift height — make sure it clears your tallest stacked product plus rigging height.
- Pick single or double girder based on the table above. If in doubt, go double girder — it is more versatile.
- Consider a double-hook trolley if you handle mixed product weights.
- Specify control type — pendant (cheapest), wireless remote (most common), or cabin (for high-volume yards).
- Confirm CE certification and FEM/ISO compliance if you export to regulated markets.
- Budget for installation at 22–35% above equipment price. Get local quotes for rail, foundation, and electrical work.
Why Precast Plants Choose SIEC Gantry Cranes
We build gantry cranes specifically for precast yard duty. A5–A7 working duty cycle for continuous daily operation. Corrosion-resistant paint and sealed electrical enclosures for outdoor exposure. Double-hook trolleys as a standard option, not a custom special. Every crane is CE certified to FEM and ISO standards. We ship to precast plants across Asia, the Middle East, Africa, and Europe.
If you want to see how a SIEC gantry crane fits your yard, send us your layout drawing and product list. We will come back with a crane spec, a price, and a recommended installation plan. No pressure, no upselling — just a straight answer on what works.
We have done this for wall panel plants in Indonesia, beam yards in Saudi Arabia, pipe plants in Vietnam, and sleeper factories in Thailand. Chances are we have seen a yard like yours before.